Portable Welding Torch Structure for Continuous Arc Stability
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Solution Overview
Problem
Portable welding robots face challenges in maintaining longtime continuous welding due to spatter drops adhering to the nozzle, leading to arc instability and welding defects, which reduces working efficiency.
Innovation Solution
A welding device and method featuring a portable welding robot with a nozzle and contact tip structure that allows relative movement, an inner nozzle diameter between 10-20 mm, and a shielding gas flow rate and velocity within specific ranges, along with a pulse waveform welding current to stabilize the arc and prevent spatter drop accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a portable welding robot performs longtime continuous welding automatically, then working efficiency is improved, but spatter drops adhere to the nozzle causing arc instability and welding defects
Solution Approach 1:
The nozzle and contact tip are designed with a relatively movable structure, allowing the contact tip to move relative to the nozzle during welding. This dynamic configuration enables the contact tip to maintain optimal positioning while the nozzle remains stable, preventing spatter accumulation at the nozzle opening and ensuring continuous arc stability during longtime welding operations
Solution Approach 2:
The welding torch is divided into functionally independent components: the nozzle that guides shielding gas and the contact tip that performs energization. This segmentation allows each component to be optimized independently - the nozzle for gas flow control and the contact tip for electrical contact - while the relative movement between them prevents spatter interference with the nozzle opening
2Reliability
If a nozzle cleaner is provided to remove spatter drops from the nozzle, then arc stability is improved, but welding must be stopped to perform removal reducing working efficiency
Solution Approach 1:
The relatively movable structure between the contact tip and nozzle enables continuous spatter removal action during welding without interruption. The contact tip can continuously scrape or brush against the nozzle inner surface to remove spatter drops as they form, maintaining arc stability throughout the welding process without requiring stopping for cleaner intervention
Solution Approach 2:
The contact tip serves dual functions: performing energization on the consumable electrode and simultaneously acting as a self-cleaning mechanism by removing spatter drops from the nozzle inner surface through its relative movement. This self-service capability eliminates the need for separate nozzle cleaner equipment and continuous welding interruptions
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables longtime continuous welding, improves working efficiency by stabilizing the arc and reducing spatter drops, thus minimizing welding defects.
Implementation Method 1
a gas supply source that supplies the shielding gas to be jetted from an end of the nozzle
Implementation Method 2
a contact tip that performs energization on a consumable electrode
Data Source
AI summary
A welding device for gas shielded arc welding includes: a portable welding robot mounted with a welding torch including a nozzle that guides jetting of shielding gas and a contact tip that performs energization on a consumable electrode; a feeding device that supplies the consumable electrode to the welding torch; a welding power source that supplies electric power to the consumable electrode via the contact tip; a gas supply source that supplies the shielding gas to be jetted from a nozzle end; and a control device that controls the portable welding robot. When the welding torch is seen from a side of jetting of the shielding gas, the contact tip is placed in an inside of an opening of the nozzle, the nozzle and the contact tip have a relatively movable structure, and an inner diameter of the nozzle end is within a range of 10-20 mm.